Engine driven converter with feedback control

ABSTRACT

A method and apparatus for welding with an engine driven inverter power supply includes generating an ac output with an engine and generator. The output is rectified and inverted to provide an ac inverter output. The engine is controlled using feedback indicative of a welding output operating parameter. The feedback may also be taken from the inverter or generator, and the generator may be controlled instead of or in addition to the engine. Engine parameters that may be controlled include engine speed, selecting between an idle speed and a run speed, a throttle position, a fuel pump, an injection timer, a fuel to air ratio, fuel consumption and ignition timing. Another aspect of the invention is having the feedback be responsive to one or more of the welding current, welding voltage, welding power, or functions thereof. The feedback may be responsive to the current, voltage, power, ripple and functions thereof. An aux power output is derived directly from the generator and feedback from the aux load is used to determine if the engine should be idling or running at high speed.

RELATED APPLICATIONS

This is a continuation of, and claims the benefit of the filing date of,U.S. patent application Ser. No. 10/629,367, filed on Jul. 29, 2003,entitled Engine Driven Invertor With Feedback Control, which issued asU.S. Pat. No. 6,894,401 on May 17, 2005, which is a continuation of, andclaims the benefit of the filing date of, U.S. patent application Ser.No. 10/262,355, filed Sep. 30, 2002, entitled Engine Driven InvertorWith Feedback Control, which issued as U.S. Pat. No. 6,674,179 on Jan.6, 2004, which is a continuation of U.S. patent application Ser. No.09/962,997, filed Sep. 24, 2001, entitled Engine Driven Invertor WithFeedback Control, which issued as U.S. Pat. No. 6,469,401, on Oct. 22,2002, which is a continuation of, and claims the benefit of the filingdate of, U.S. patent application Ser. No. 09/542,974, filed Apr. 4,2000, entitled Engine Driven Invertor With Feedback Control, whichissued an U.S. Pat. No. 6,310,321 on Oct. 30, 2001, which is acontinuation of U.S. patent application Ser. No. 09/238,361, filed Jan.27, 1999, entitled Engine Driven Invertor With Feedback control, whichissued as U.S. Pat. No. 6,111,217, on Aug. 29, 2000, and which is acontinuation of U.S. patent application Ser. No. 08/858,129, filed May19, 1997, entitled Engine Driven Invertor With Feedback Control, whichissued as U.S. Pat. No. 5,968,385 on Oct. 19, 1999.

FIELD OF THE INVENTION

The present invention relates generally to the art of welding powersupplies. More specifically, it relates to inverter welding powersupplies driven by an engine.

BACKGROUND OF THE INVENTION

There are different types of prior art welding power supplies. Two typesof welding power supplies are phase controlled and inverter-based powersupplies. Both types typically receive an ac line (60 Hz) input.However, inverter power supplies can be controlled to a desiredfrequency, but phase controlled power supplies are limited to the inputfrequency. Also, phase controlled power supplies cannot be used forpulse spray processes. Inverter-based power supplies are often preferredbecause they are lighter, have a faster response, provide better weldcharacteristics, and are better suited for multiple processes (MIG, TIG,stick etc.).

An inverter power supply receives a dc input (often called the dc bus),and switches the input to provide an ac output. Prior art inverterwelding power supplies have been designed to receive a line frequencyinput (60 or 50 Hz), and to rectify that input to produce the dc bus.

The inverted ac output can be, used as the welding output. However, someprior art welding power supplies include a rectifier which rectifies theac inverter output to provide a dc welding output. The dc input to theinverter is typically obtained by rectifying an ac line input. Manyinverter power supplies have controls which allow the power supply toeffectively convert the ac line power into useful dc (and sometimes ac)welding power.

Engine driven generators used in welding are also common. An enginedriven welding power supply is necessary for applications where the userneeds to weld at multiple locations and finds it necessary to move thewelding power supply. An auxiliary power output (110 or 220 VAC) isusually provided for power tools, lights etc. Typically, engine drivengenerators are used to drive a simple tapped reactor or phase controlledpower supplies. They often require an engine and generator specificallydesigned for the welding power supply, which can be more expensive thanusing a standard engine/generator. Phase controlled engine drive weldingpower supplies necessarily include all of the disadvantages of phasecontrolled power supplies.

Another prior art engine driven welding power supply is a dc weldingpower supply, wherein the dc output of the generator is used directlyfor a dc welding output. Such a welding power supply, with fieldcontrol, is shown in U.S. Pat. No. 4,465,920, issued to Hoyt et al.

A few prior art inverter welding power supplies have been connected to agenerator output and used as engine driven inverter welding powersupplies. The generator ac output serves as the ac inverter input (whichis rectified to create the dc bus). This arrangement creates manyproblems. First, inverter based welding power supplies have heretoforebeen designed to receive the relatively stable and constant ac linevoltages. A generator does not always produce such a stable and constantoutput. Second, there has not been an integrated control system whereinthe engine and or generator is controlled in response to the weldingoutput or inverter operating parameters. Thus, these engines usuallyoperate at full throttle constantly, and are very inefficient.

The common practice of providing an auxiliary power output on thegenerator has at least one disadvantage. The auxiliary power is singlephase, 120 or 240 VAC at 50 or 60 Hz, and is used for power tools,lights etc. However, the single phase output unbalances the three phaseoutput, and the result is harmonic distortion in all three phases. Thedistortion will cause one of the phases to have much higher peak voltagethan the other two phases. The unusually high peak voltage may damagethe inverter input capacitors, or require larger capacitors.

The distortion is caused by a backward component of a magnetic fieldwave. When a three phase load is present the three stator currentsproduce a magnetic field wave that rotates in the same direction as, andat the same speed as, the rotor. Thus, there is no relative motionbetween the rotor and the magnetic field wave, and the magnetic fieldwave does not induce any voltage in the rotor. However, when the load isunbalanced the magnetic field wave created by the stator currents doesnot move at the speed as and in the same direction as the rotor. Themagnetic field produced by the stator currents when an unbalanced loadis present may be resolved into two components: a forward component thatis in the same direction and at the same speed as the rotor, and abackward component. The forward component behaves as a balanced threephase load, and does not cause a problem. The backward component ismoving at the same speed as the rotor, but in the opposite direction.Thus, it has a motion relative to the rotor of twice the generatorspeed. This “moving” magnetic field will induce voltage in the rotorfield winding, which causes the high output voltage. Damper cages havebeen used in generators (although not necessarily in the welding art) tocounter-act or compensate for the effect of unbalanced loads.

Accordingly, it would be beneficial to have an inverter-based weldingpower supply that is engine driven where the control is integrated tocontrol the engine and generator in response to either welding orinverter operating parameters. Preferably the generator will counter-actor compensate for the effect of unbalanced loads. Also, the power supplywill preferably be able to be used for pulse spray and other weldingprocesses.

SUMMARY OF THE PRESENT INVENTION

According to a first aspect of the invention a method for providingwelding power includes generating an electrical output with an engineand an ac or dc generator. The output is rectified if needed, andinverted to provide an ac inverter output. The engine is controlledusing feedback indicative of a welding output operating parameter.

Another aspect of the invention is controlling engine speed in responseto the feedback. Also, the speed may be specifically controlled toselect between an idle speed and a run speed in response to thefeedback. Other aspects include controlling one or more of a throttleposition, a fuel pump, an injection timer, a fuel to air ratio, fuelconsumption and ignition timing.

Another aspect of the invention is having the feedback be responsive toone or more of the welding current, welding voltage, welding power, orfunctions thereof.

Another aspect of the invention is obtaining a signal responsive to theoutput power and a function thereof by multiplying signalsrepresentative of the voltage and current to obtain a signalrepresentative of the power, and then integrating the signalrepresentative of the power.

Yet another aspect of the invention includes the step of storing energyafter rectifying, and controlling the engine by increasing engine speedwhen the energy stored decreases past a threshold.

One alternative aspect of the invention is having the feedback beresponsive to ripple in the output. Another alternative aspect includesthe step of rectifying the inverter output to provide a dc weldingoutput.

Another aspect of the invention is a stand alone welding power supplythat includes a primary mover mechanically coupled to a rotating shaft.A generator includes a rotor mechanically coupled to the shaft and thegenerator also includes a stator magnetically coupled to the rotor.Thus, the generator provides an ac output. An inverter is connected tothe ac output through a rectifier and the inverter inverts power fromthe ac input to provide an inverted output. A controller is coupled tothe engine and has a feedback input connected to a feedback circuit. Thefeedback circuit is also coupled to the welding output, and a signalresponsive to at least one welding output operating parameter isprovided to the feedback input. A dc generator, without subsequentrectification, is used in another embodiment.

Yet another aspect of the invention incudes a speed control for theprimary mover and the controller includes an output coupled to the speedcontrol, wherein the speed of the primary mover is controlled inresponse to the feedback signal. One embodiment provides for selectingbetween an idle and run speed in response to the feedback signal.Alternatives include controlling one or more of a throttle position, afuel pump, an injection timer, a fuel to air ratio, fuel consumption andignition timing.

Other aspects of the invention include deriving the feedback fromwelding current, welding voltage, welding power, ripple current, ripplepower, ripple voltage and/or functions thereof. The power and a functionthereof may be obtained from a circuit that multiplies signalsrepresentative of voltage and current to obtain a signal representativeof power, and a circuit that integrates the signal representative ofpower.

Yet another aspect of the invention includes one or more input energystorage device that stores energy after rectification and wherein thecontroller causes the engine to increase speed when the energy storeddecreases past a threshold.

Another aspect includes a rectifier coupled to the inverter output toprovide a dc welding output.

Other principal features and advantages of the invention will becomeapparent to those skilled in the art upon review of the followingdrawings, the detailed description and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram of the preferred embodiment of the presentinvention;

FIGS. 2A and 2B are graphs showing power and integrated power;

FIG. 3 is a schematic of part of a controller for controlling enginespeed;

FIG. 4 is a control diagram for a generator field current controller;

FIGS. 5–7 are circuit diagrams which implement the control diagram ofFIG. 4;

FIG. 8 is an end view of a damper cage;

FIG. 9 is a side end view of the damper cage of FIG. 8;

FIG. 10 is a sectional view of the damper cage of FIG. 8, taken alonglines 10—10; and

FIG. 11 is a circuit diagram of a delay circuit used in the preferredembodiment.

Before explaining at least one embodiment of the invention in detail itis to be understood that the invention is not limited in its applicationto the details of construction and the arrangement of the components setforth in the following description or illustrated in the drawings. Theinvention is capable of other embodiments or of being practiced orcarried out in various ways. Also, it is to be understood that thephraseology and terminology employed herein is for the purpose ofdescription and should not be regarded as limiting. Like referencenumerals are used to indicate like components.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

While the present invention will be illustrated with reference to aparticular engine, generator, converter, controller and feedback system,it should be understood at the outset that the invention may include theaddition of other components, removal of components, or the substitutionfor components. The preferred example, including component values, isnot limiting, rather it as exemplary. One skilled in the art should beable to use Other components and component values to implement thisinvention. This invention relates to a stand-alone welding power supply.As used herein, stand alone means a welding power supply that includes agenerator, rather than a welding power supply which derives power fromthe ac line power line. In other words, a stand alone welding powersupply produces power, rather than converts ac line power. Also, a standalone welding power supply may have the mechanical and electricalportions in a single case, it may be modular, or the engine, generatorand electrical power supply may each be separate.

A block diagram of an engine driven inverter based welding power supply100 is shown in FIG. 1, where the thick black lines indicate powertransmission, and the thin lines indicate control or feedback signals.Welding power supply 100 includes an engine 102, a generator 104, an auxpower output 105, a rectifier 106, a converter 108, a controller 110,and a welding output 112. Generally speaking, engine 102 is a gas ordiesel powered engine (a primary mover) that drives a shaft on which arotor of generator 104 is mounted. Any engine suitable for the desiredpower output may be used, and in the preferred embodiment the engine isa commercially available diesel engine, model DH905 or DH1005, made byKubota. This model includes a lever that is used to select betweenidling speed and a run (or higher) speed. As used herein run and runningspeed refer to a higher than idle speed.

Generator 104 may be a typical generator having a rotor and stator, and,in the preferred embodiment, is designed by using a single phasegenerator such as that used in the Metro™ welding power supply availablefrom the assignee of this invention. The auxiliary and welding windingof the Metro™ are replaced with three phase windings for this invention.The rotor is magnetically coupled with the stator, and a field currentis supplied such that when the rotor is turned, an ac output current isproduced.

The electrical output of generator 104 is provided to a rectifier 106,which produces rectified dc power. The rectified dc power is provided toconverter 108, which includes, in the preferred embodiment, at least oneenergy storage device such as a capacitor 107 for smoothing the ripplein the rectified signal to provide a dc bus. An alternative embodimentuses a dc generator instead of ac generator 104 and rectifier 111, orrectifier 111 may be part of generator 104, or between generator 104 andconverter 108.

Converter 108 also includes, in the preferred embodiment, an inverter109 and rectifier 111 that convert the smoothed and rectified dc signalto a welding output (having an appropriate current and voltage).Converter 108 is in the preferred embodiment, a series resonantconverter that inverts the dc bus and an output rectifier to produce adc welding current as the welding output 112. An ac output is used in analternative embodiment A suitable series resonant converter is describedin detail in U.S. patent application Ser. No. 08/584,412, which is ownedby the assignee of the present invention, and is hereby incorporated byreference. This converter is also available commercially, from theassignee of the present invention, as the XMT304™ power supply.

As described in application Ser. No. 08/584,412, a power control circuit113 is included in converter 108 such that the welding current isselected by the operator, and the converter provides the desiredcurrent. Various control functions including a hot start and aprotection system are also described therein. Modifications to theXMT304™ series resonant converter to adapt it to this invention includesremoving the autolink feature and reducing the OCV command. Additionalmodifications are described below.

One advantage of using the preferred power source is that it readilyadaptable to use in a wide range of welding processes. For example, byincluding an Optima™ or 60M™ controller, each available from the presentassignee, a pulse spray process may be performed. Other processesinclude short arc, spray CV, spray CC, CC stick, CC TIG, pulse MIG, orpulse TIG (for example using a PC300™ controller). These process may beperformed using the inventive engine driven inverter welding powersupply.

Other converters, such as hard switched inverters, may also be used toimplement the present invention. The specific converter or inverterselected is not important, so. long as it, is properly controlled toprovide the desired output current. Converter, as used herein, is aswitched circuit that converts an ac or dc input to a different ac or dcoutput. Inverter, as used herein, is a switched circuit having a dcinput and provides an ac output, or one that has an ac input and arectifier to produce a dc signal that is then switched to produce an acoutput that may. Also, an inverter, as used herein, may include anoutput rectifier to produce a dc output.

Controller 110 is provided to control the engine in response to feedbackfrom the welding output. Feedback, as used herein, includes a signalindicative of or responsive to an output or intermediate signal, whichis provided to the controller and which control decisions are made inresponse thereto. Feedback is not intended to encompass the userobserving the process and the user making adjustments in response to-theobservations. The feedback signal may be any welding operatingparameter, such as current, voltage, frequency, power, ripple current,ripple magnitude, ripple voltage, ripple frequency, or functionsthereof. The specific parameter fedback may be mathematically operatedon as required by the control scheme.

One alternative embodiment includes the control of the generator bycontroller 110, as shown by the arrow from controller 110 to generator104. However, this control should be considered as an alternative to, oran optional addition to, the control of engine 102 by controller 110.Also, the control scheme of the preferred embodiment is not intended tobe limiting. Rather, the invention broadly encompasses feedback in awelding power supply to control an engine/generator.

Specifically, in the preferred embodiment, controller 110 includes afeedback circuit 114 that is connected to the welding studs to obtain awelding current and welding voltage feedback signal. The specificfeedback circuit will be described in detail later. Feedback circuit 114is, in an alternative embodiment, separate from controller 110. However,whether it is separate from, or part of, controller 110 is not importantfor the present invention. Also, controller 110 may be on the samecircuit board as control circuit 113. It may be useful to makecontroller 110 part of control circuit 113 since they may share feedbacksignals.

Controller 110 uses the feedback signal to determine the input powerneeded by converter 108. Then, the speed of engine 102 is adjusted toprovide that needed power. Generally, an engine speed control iscontrolling the speed of the engine, which controls the power output ofthe generator. Specifically, in the preferred embodiment, controlcircuit 113 causes engine 102 to operate at either an idle speed, or arun speed (close to or at full throttle). A solenoid may be used to movethe run/idle lever to the desired position. Alternatively, more than twopositions (run/idle) or a continuous range of positions may be selected,based on the power needed. One alternative embodiment includes usingcontroller 110 to control at least one of a throttle position, a fuelpump, an injection timer, a fuel to air ratio, fuel consumption andignition, timing.

The decision to operate at idle or run is made based on an integratedpower in the preferred embodiment. This allows the operating speed ofengine 702 to be determined from energy needed instead of instantaneousor peak power.

More specifically, as stated above, converter 108 includes a “hot start”feature wherein the power draw at the start of a weld is momentarilyhigh to aid in striking of the arc and preventing sticking of the arc.This will cause a high peak or instantaneous power draw. However, thetotal energy used in such a hot start is not of a sufficient magnitudeto decrease the energy stored by capacitor(s) 107 to a level at whichthe inverter will not operate properly. Thus, controller 110 integratesthe power at welding output 112 (which is directly related to the energydrained from capacitor(s) 107). When the integrated power exceeds athreshold, based on how much energy can be drained from capacitor(s)107, the engine is caused to operate at high speed. The engine continuesto run at high speed until power being drawn is no longer above thethreshold.

The engine, in the preferred embodiment, provides 4 Kw of inverteroutput power in the idle mode. Thus, so long as the converter does notoutput more than 4 Kw of power the engine produces as much power asneeded while idling. If more than 4 Kw of power is output by converter108 for a short period of time (such as during the hot start) the enginedoes not need to speed up. Thus, the inverter output power isintegrated, to the extent it exceeds about 4 Kw. When the integrandexceeds a threshold, the engine is caused to run at a higher speed. Theintegrand is reset to zero periodically.

FIG. 2A illustrates this control scheme. Power (at the welding studs) isplotted on the Y axis, and the X axis indicates time. The 4 Kw idleoutput is shown with a dashed line. The graphs shows that the weldingset point is below 4 Kw, thus, on a long-term basis the engine canprovide sufficient power while idling. However, as may be seen, the “hotstart” causes the instantaneous power to exceed 4 Kw. Controller 110integrates the cross hatched area, which is the energy drain on thecapacitors when the engine is idling. FIG. 2B shows the integrandplotted over time. If the integrand exceeds the run threshold, thencontroller 110 causes engine 102 to operate at a higher speed.

One alternative embodiment of controller 110 includes circuitry todecide whether to run at idle or high speed based on the machinesettings. When an operator is going to weld, they set controls(typically on a power supply front panel) indicating the weldingparameters, such as current, process, voltage, etc. The setting may bedialed or typed in, and controller 110 monitors one or more of thesesettings, and determines from a look-up table, microprocessor, or analogcircuit whether or not the engine will need to operate at running speed,or if idling will suffice. The throttle lever is moved in accordancewith that determination.

FIG. 3 is the circuit diagram of a multiplier 301 and an integrator 302of controller 110. A signal V_(fb) is responsive to the welding outputvoltage, and is provided through a circuit including a plurality ofresistors R1 (100K ohms), R2 (2K ohms), R3 (100K ohms), R4 (45K ohms),R4A (100K ohms) and R5 (3.32K ohms), a pair of op amps A1 and A2, a pairof capacitors C1 (330 μF) and C2 (47 pF), a diode D1 and a pair oftransistors T1 and T2. The components are arranged such that the signalprovided to the base of a transistor T5 is indicative of the voltagemagnitude.

A signal I_(fb) is responsive to the welding output current, and isobtained using a LEM. I_(fb) and is provided through an op amp A10,including a pair of resistors R10 (100K ohms) and R11 (150 ohms), and acapacitor C10 (22 Pf), a diode D10 to the collector of transistor T5. Afeedback resistor R12 is also provided. Another transistor T10, acapacitor C11 (0.001 μF), a resistor R13 (10K ohms) and an op amp A11are connected to the emitter of transistor T5 such that the output of opamp A11 is a signal indicative of and responsive to the power at thewelding studs (i.e. a power feedback signal).

The power feedback signal is provided to integrator circuit 302 whichincludes an op amp A15 and resistors R18 (10K ohms), R16 (562K ohms),R17 (12.1K ohms) and a feedback capacitor C18 (0.1 μF). The output of opamp A15 is the integrated power when the power exceeds 4 Kw, and is usedby controller 110 to determine when to cause the engine to operate atrun speed. Resistors R16 (562K ohms) and R17 (12.1K ohms) set the 4 KWlevel, and resistor R18 (10K ohms) and capacitor C18 (0.1 μF) provide anRC integrating time constant. The decision can be made by controller 110using a simple comparator having a threshold as one input and the outputof op amp A15 as the other input.

FIG. 4 shows a voltage regulator 401 that regulates the voltage ofgenerator 104. Voltage regulator 401 is part of controller 110 in thepreferred embodiment, although it may be separate from controller 110.Generally, voltage regulator 401 controls the generator field currentsuch that the output voltage of the generator is at a desired level.

Specifically, a rectifier/scaler 402 receives the three phase generatoroutput voltage, and rectifies and scales it. A voltage command 404receives as an input the signal indicating whether the engine is in therun or idle mode, and provides a set point command signal to an adder406. Thus, the set point command is one of two values, depending uponwhether the engine is idling or running at high speed. Adder 406 alsoreceives the scaled three phase voltage and its output is an errorsignal. The error signal is provided to a gain stage 407, and then to anadder 408.

A frequency sensor 410 senses the frequency of the generator (which isindicative of engine speed) and provides a signal to a limiter 411 thatis used by adder 408 to limit the field current. Frequency sensor 410receives as another input the run/idle command, and different fieldcurrent limits are set, depending on whether the engine is running athigh speed or idling. Thus, adder 408 provides a field current commandsignal that is a function of the error, and is limited by theengine/generator frequency and the run/idle selection.

The field current command signal is provided to an adder 412, which alsoreceives a field current feedback signal. The output of adder 412 is thedifference between the field current command and feedback, and is thus afield current error signal. The error signal is provided to another gainstage 414. A PWM chip 416 compares the field current error signal to athreshold, and turns on and off a transistor as need. The transistorconnects the 120 VAC field power to the field of generator 104.

A circuit which implements this scheme is shown in FIGS. 5–7.Rectifier/scaler 402 is shown schematically on FIG. 5, and includesthree identical circuits, each of which has a unique two of the threephases as inputs. Generally, each circuit includes nine feedback andscaling resistors (R20–50), two op amps (A20–A25), and a capacitor(C20–C22). The components have the following values: resistors R20, R24and R28 are 332K ohms, resistors R21, R25 and R29 are 16.2K ohms,resistors R22, R26 and R30 are 332K ohms, resistors R23, R27 and R31 are16.2K ohms, resistors R33, R34 and R35 are 12.1K ohms, resistors R36,R37 and R38 are 12.1K ohms, resistors R41, R42 and R43 are 10K ohms,resistors R44, R45 and R46 are 10K ohms, resistors R48, R49 and R50 are100K ohms and capacitors C20, C21 and C22 are 0.01 μF. The output issummed and buffered by op amp A27 and resistor R47 (15K ohms) andcapacitor C40 (0.01 μF).

Voltage command 404 includes resistor R51 (10.8K ohms) and R52 (6.75Kohms) and a relay CR1. One of the contacts of CR1 is open, and the otherclosed, depending on whether idle or run is selected.

Adder 406, gain stage 407, and adder 408 are also shown on FIG. 5. Theyinclude an op amp A30, a feedback resistor R55 (3.32K ohms), a feedbackcapacitor C42 (1 μF), and a transistor T20. These components areconfigured to provide an output that is the error of the voltage commandfrom the setpoint, limited by the frequency sense circuit 410.

Frequency sense circuit 410 is shown on FIG. 6 and receives an inputfrom scaler/rectifier 410. That input is provide through a resistor R61(475K ohms) to a frequency-voltage converter chip FVC1.Frequency-voltage converter chip FVC1 is conventionally configured andincludes associated components resistors R62. (10K ohms) and resistorsR63, and capacitors C60 (0.1 μF) and C61 (1 μF). The output of FVC1 isprovided to an op amp A60, which includes associated componentsresistors R64 (1K ohms), R65 (18.2K ohms), R66 (8.25 ohms), R67 (1Mohms) and R69 (2K ohms). The idle/run select signal is provided througha transistor T60 and resistors R70 (10K ohms) and R68 (7.5K ohms) to oneinput of op amp A60.

Frequency sense circuit 410 also includes three NAND gates, NAND1,NAND2, and NAND3. The NAND gates, along with a pair of analog switchesS60 and S61, and associated circuitry resistors R72 (20K ohms) and R73(1.53K ohms), R75 (3.92K ohms), R76 (1.74K ohms) and transistor T61, areconfigured top provide the limiting signal to adder 408.

One alternative embodiment includes using frequency sense circuit 410 oran alternative circuit to determine if the engine is slowing down to thepoint where a stall is likely. If controller 110 determines that a stallis likely, then the converter controller may be over-ridden such thatthe output is temporarily reduced, until the likelihood of a stall isreduced.

FIG. 7 is a schematic of adder 412 and gain stage 414, along with PWMchip 416. The field current feedback signal is scaled by an op amp A80and resistors R80 (10K ohms), R81 (56K ohms) and R82 (10K ohms).Capacitor C80 is 0.01 μF. The output of op amp A80 is summed with thecommand signal from adder 408 by op amp A81 and a resistor R84 (100Kohms) to provide the error signal. An op amp A82, and resistors R85 (10Kohms) and R86 (10K ohms) provide the gain stage. The output of gainstage 414 is provided through a resistor R87 (3.32K ohms) to a PWM chipIC1 that is configured in a conventional manner to turn on and off atransistor T80 and provide a current to a field winding FW1, a pair ofbrushes B1 and B2, and a pair of slip rings S1 and S2, in accordancewith a desired current level.

Many welding power supplies that operate on an ac power line include anunder voltage protection circuit thus, when the input voltage dropsbelow a threshold a switch is turned on (or off) such that and the powersupply controller shuts down the power supply. However, if the load ofan engine driven welding power supply increases when the engine isidling, a transient voltage dip occurs. Thus, if the convertercontroller includes an under voltage protection circuit, it must beremoved or modified to accommodate the relatively slow response of theengine.

One embodiment of the present invention includes the use of an RC delaycircuit in the under voltage protection circuit that begins to chargewhen the under voltage switch is turned on. The capacitor continues tocharge so long as the switch is on. After a sufficient delay, (1 sec inthe preferred embodiment) the under voltage lockout mechanism isactivated. The delay circuit is shown in FIG. 11 and the low voltagedetect signal is provided through a diode D90 and a 1M ohm resistor R90to charge a 1 μF capacitor C90. When capacitor C90 is charged the lowvoltage protection shut off signal is provided, but a transient lastingless than the time it takes to charge capacitor C90 (1 sec) is ignored.Capacitor C90 is discharged rapidly through a 100K ohm resistor R92 anda diode D92, by a transistor T92. Transistor T92 is turned on by a 2Kohm resistor R93 when the low voltage is not detected. The preferredembodiment uses a 24 volt control board power for the under voltageinput, which is derived from, and directly proportional to, the ac inputvoltage; to check for under voltage.

The preferred embodiment includes the use of a single phase auxiliarypower output, 120 VAC at 60 Hz, for power tools, lights etc. 240 VACand/or 50 hz may also be provided. The auxiliary power may be takendirectly from the generator, without pre-conditioning, or it may bepre-conditioned. A damper cage is provided, in the preferred embodiment,to counteract the unbalanced load. Generally, a damper cage is a seriesof low resistance conductors close to the surface of the rotor polebodies. The damper cage acts as a low impedance winding on the rotor.The backward magnetic field wave from the stator currents (caused by thesingle phase load) induces large amounts of current in the damper cagebars. This current induces a magnetic field which tends to cancel thebackward magnetic stator wave.

Specifically, in the preferred embodiment, the damper cage includesseven aluminum rods 0.25 inches in diameter placed in closed slots.FIGS. 8–10 show an end view, side view, and sectional view,respectively, of a rotor having a damper cage in accordance with thepresent invention. The rotor is mounted on a shaft 801 and includeswinding 802. The seven aluminum bars 803 may be seen in FIGS. 9 and 10.The slots the bars are placed in are, in the preferred embodiment, 0.26inches in diameter, and 0.03 below the surface. The damper cage iscompleted with an aluminum piece, cut to the same shape as thelamination, on each end. The rods are TIG welded to the end pieces.Alternative methods of construction include using copper rods silversoldered to copper end pieces, copper rods brazed or welded to a copperring end piece, or aluminum die casting through the rotor holes. Theembodiment shown is a two pole generator, but a generator with four ormore poles could also be used.

The preferred embodiment monitors the demand of the aux load, and ifnecessary causes the engine to run at high speed in response to the auxload. One alternative embodiment that also reduces distortion from theauxiliary power output is to include an aux power feedback circuit incontroller 110. Another is to add a large capacitor on the leg whichreceives the higher voltage. Also, multiple stators may also reducedistortion caused by an unbalanced load.

One alternative embodiment is shown by the dashed control lines in FIG.1 between controller 110 and converter 108. The feedback signal isobtained from the inverter, rather than the welding output in thisembodiment. Controller 110 uses the feedback to determine the desiredengine speed. The selected speed may be one of at least two discreetspeeds (idle/run e.g.) or from a continuous spectrum of speeds. Theparameters used for feedback include one or more of inverter outputand/or tank current, inverter output and/or tank voltage, inverteroutput and/or tank power, ripple parameters and frequency. The “tank”feedback signals may be particularly appropriate when the converter is aseries resonant converter. Another alternative includes using an outputtransformer, and deriving the feedback signals (such as those describedabove) from the secondary side of the transformer). The feedback signalmay, as described above, be a mathematical function of the operatingparameter. Another alternative includes controlling at least one of athrottle position, a fuel pump, an injection timer, a fuel to air ratio,fuel consumption and ignition timing of the engine.

Other alternatives include controlling the engine based on a generatoroperating parameter feedback. The generator operating parameter may befield current, generator output (or inverter input) current, voltage,power, frequency, or aux current, voltage, power or frequency. Asdescribed above, the fedback signal may be a mathematical function ofthe operating parameter. Also as described above, the engine parameterbeing controlled may be speed, throttle position, a fuel pump, aninjection timer, a fuel to air ratio, fuel consumption and ignitiontiming.

Another alternative is to control the generator in response to thewelding and converter operating parameters described above. The fieldcurrent is controlled in one alternative embodiment.

Other alternatives include controlling the inverter so it operates moreeffectively with a generator input. One such alternative is describedabove, wherein the inverter is controlled so that it can operate at lowvoltages for a period of time. Another alternative is to provide apre-regulator between the generator and the converter so that the inputmimics ac line power. The pre-regulator may include power factorcorrection, a rectifier, large capacitors or energy storage devices, anda controlled bridge. One alternative embodiment includes a soft switchedconverter as the pre-regulator, and another is a voltage converter asthe pre-regulator. The pre-regulator may be particularly useful when theaux power is derived directly from the generator. Alternatively, the auxpower may be pre-regulated. Another alternative is using a 60 Hzinverter to produce the aux power. Either single or three phase can beused as an input to the aux inverter.

Numerous modifications may be made to the present invention which stillfall within the intended scope hereof. Thus, it should be apparent thatthere has been provided in accordance with the present invention amethod and apparatus for welding with an engine driven inverter thatfully satisfies the objectives and advantages set forth above. Althoughthe invention has been described in conjunction with specificembodiments thereof, it is evident that many alternatives, modificationsand variations will be apparent to those skilled in the art.Accordingly, it is intended to embrace all such alternatives,modifications and variations that fall within the spirit and broad scopeof the appended claims.

1. A stand alone power supply comprising; a primary mover mechanicallycoupled to a rotating shaft; a generator having a rotor mechanicallycoupled to the shaft, and further having a stator magnetically coupledto the rotor, whereby the generator provides a generator output; a powerconverter having a converter input in electrical communication with thegenerator output, wherein the converter converts power from theconverter input to provide a converter output; a controller coupled tothe primary mover and having a feedback input; and a feedback circuitcoupled to the converter output and the feedback input wherein afeedback signal responsive to at least one converter output operatingparameter, including a function of a ripple in the output, is providedto the feedback input.
 2. The power supply of claim 1 wherein theprimary mover includes a speed control and the controller includes anoutput coupled to the speed control, wherein the speed of the primarymover is controlled in response to the feedback signal.
 3. The powersupply of claim 2 wherein the speed control includes an idle/runselector for selecting between an idle speed and a run speed in responseto the feedback signal.
 4. The power supply of claim 1 wherein thecontroller includes means for controlling at least one of a throttleposition, a fuel pump, an injection timer, a fuel to air ratio, fuelconsumption and ignition timing.
 5. The power supply of claim 1 whereinthe at least one operating parameter is a converter current.
 6. Thepower supply of claim 5 wherein the at least one operating parameterfurther includes a converter voltage.
 7. The power supply of claim 1wherein the at least one operating parameter is a converter voltage. 8.The power supply of claim 1 further including a rectifier coupled to theconverter output to provide a dc converter output.
 9. The power supplyof claim 1 wherein the generator is a dc generator.
 10. The power supplyof claim 1 wherein the generator is an ac generator, and the converterincludes an input rectifier.
 11. A stand alone power supply comprising;a primary mover mechanically coupled to a rotating shaft; a generatorhaving a rotor mechanically coupled to the shaft, and further having astator magnetically coupled to the rotor, whereby the generator providesa generator output; a power converter having a converter input inelectrical communication with the generator output, wherein theconverter converts power from the converter input to provide a converteroutput; and a controller coupled to the primary mover and having afeedback input; a feedback circuit coupled to the converter output andthe feedback input wherein a feedback signal responsive to convertercurrent and converter voltage is provided to the feedback input, whereinthe feedback circuit includes a multiplier, wherein the multipliermultiplies signals representative of voltage and current to obtain asignal representative of power, and further wherein the feedback circuitincludes an integrator to integrate the signal representative of power.12. A stand alone power supply comprising; a primary mover mechanicallycoupled to a rotating shaft, wherein the primary mover includes a speedcontrol; a generator having a rotor mechanically coupled to the shaft,and further having a stator magnetically coupled to the rotor, wherebythe generator provides a generator output; a power converter having aconverter input in electrical communication with the generator output,wherein the converter converts power from the converter input to providea converter output; a controller coupled to the primary mover and havinga feedback input, and wherein the controller includes an output coupledto the speed control; and a feedback circuit coupled to the converteroutput and the feedback input wherein a feedback signal responsive to atleast one converter output operating parameter is provided to thefeedback input, and wherein the speed of the primary mover is controlledin response to the feedback signal; and a rectifier that couples theconverter to the ac output, and wherein the converter includes at leastone input energy storage device that stores rectified energy and whereinthe controller causes the primary mover to increase speed when theenergy stored decreases past a threshold.
 13. A stand alone power supplycomprising; a primary mover mechanically coupled to a rotating shaft; agenerator having a rotor mechanically coupled to the shaft, and furtherhaving a stator magnetically coupled to the rotor, whereby the generatorprovides a generator output; a converter having a converter input inelectrical communication with the generator output, wherein theconverter converts power from the converter input to provide a converteroutput; control means, coupled to the primary mover and having afeedback input, for controlling the primary mover; and feedback means,coupled to the converter output and the feedback input, for providing afeedback signal responsive to at least one converter output operatingparameter, including a function of a ripple in the output, to thefeedback input.
 14. The power supply of claim 13 wherein the primarymover speed control means for controlling the primary mover's speed, andthe control means includes an output coupled to the speed control means,wherein the speed of the primary mover is controlled in response to thefeedback signal.
 15. The power supply of claim 14 wherein the speedcontrol means includes an idle/run selector means for selecting betweenan idle speed and a run speed in response to the feedback signal. 16.The power supply of claim 13 wherein the control means includes meansfor controlling at least one of a throttle position, a fuel pump, aninjection timer, a fuel to air ratio, fuel consumption and ignitiontiming.
 17. The power supply of claim 13 wherein the at least oneoperating parameter is converter current.
 18. The power supply of claim17 wherein the at least one operating parameter further includesconverter voltage.
 19. The power supply of claim 13 wherein the at leastone operating parameter is converter voltage.
 20. The power supply ofclaim 13 further including a rectifier means coupled to the converteroutput for providing a dc converter output.
 21. The power supply ofclaim 13 wherein the generator is a dc generator.
 22. The power supplyof claim 13 wherein the generator is an ac dc generator and theconverter includes a rectifier.
 23. A stand alone power supplycomprising; a primary mover mechanically coupled to a rotating shaft; agenerator having a rotor mechanically coupled to the shaft, and furtherhaving a stator magnetically coupled to the rotor, whereby the generatorprovides a generator output; a converter having a converter input inelectrical communication with the generator output, wherein theconverter converts power from the converter input to provide converteroutput; control means, coupled to the primary mover and having afeedback input, for controlling the primary mover; feedback means,coupled to the converter output and the feedback input, for providing afeedback signal responsive to converter current and converter voltage tothe feedback input; and wherein the feedback means includes a multipliermeans for multiplying signals representative of voltage and current toobtain a signal representative of power, and further wherein thefeedback means includes an integrator means for integrating the signalrepresentative of power.
 24. A stand alone power supply comprising; aprimary mover mechanically coupled to a rotating shaft and having aspeed control means for controlling the primary mover's speed; agenerator having a rotor mechanically coupled to the shaft, and furtherhaving a stator magnetically coupled to the rotor, whereby the generatorprovides a generator output; a converter having a converter input inelectrical communication with the generator output, wherein theconverter converts power from the converter input to provide a converteroutput; control means, coupled to the primary mover and having afeedback input, for controlling the primary mover, and including anoutput coupled to the speed control means; and feedback means, coupledto the converter output and the feedback input, for providing a feedbacksignal responsive to at least one converter output operating parameterto the feedback input, wherein the speed of the primary mover iscontrolled in response to the feedback signal; and wherein the converterincludes at least one input energy storage means for storing energy tobe converted by the converter, and wherein the control means furtherincludes means for increasing primary mover's speed when the energystored decreases past a threshold.